3D printed ball valve

Abstract

A ball valve that includes a ball comprising an integrally formed single-component body that defines an external surface; a fluid passage extending through the body, the fluid passage defining an internal surface; and a plurality of internal chambers formed within the body, each internal chamber of the plurality of internal chambers being spaced from the external surface and being spaced from the internal surface; wherein when the ball is subjected to one or more stresses, a stress concentration is created within a release-by-milling zone of the single-component body, the release-by-milling zone being adjacent to the plurality of internal chambers. The ball is at least partially manufactured using an additive manufacturing process.

What is claimed is: 
     
       1. A ball valve, comprising:
 a ball comprising an integrally formed single-component body that defines: 
 an external surface; 
 a fluid passage extending through the body, the fluid passage defining an internal surface; and 
 a plurality of internal chambers formed within the body, each internal chamber of the plurality of internal chambers being spaced from the external surface and being spaced from the internal surface; 
 
       wherein the body forms a first external planar surface and an opposing second external planar surface;
 wherein the body comprises a first projection extending from the first external planar surface and a second projection extending from the second external planar surface; 
 wherein when the ball is subjected to one or more stresses, a stress concentration is created within a release-by-milling zone of the single-component body, the release-by-milling zone being adjacent to the plurality of internal chambers. 
 
     
     
       2. The ball valve of  claim 1 , wherein the plurality of chambers formed within the body form a lattice structure within the body. 
     
     
       3. The ball valve of  claim 1 ,
 wherein each internal chamber of the plurality of internal chambers is fluidically isolated from the external surface; 
 wherein the body comprises a first material; 
 wherein a second material is accommodated within one internal chamber of the plurality of internal chambers; and 
 wherein the first material is different from the second material. 
 
     
     
       4. The ball valve of  claim 1 , wherein a vent extends from the external surface and to one internal chamber of the plurality of internal chambers. 
     
     
       5. The ball valve of  claim 4 ,
 wherein the body forms a first external planar surface and an opposing second external planar surface; and 
 wherein the vent extends from at least one of the first external planar surface and the second external planar surface. 
 
     
     
       6. The ball valve of  claim 4 , wherein a passageway extends from the one internal chamber to another internal chamber of the plurality of internal chambers. 
     
     
       7. The ball valve of  claim 1 , further comprising a ball seat;
 wherein the body forms a top portion and an opposing bottom portion; 
 wherein the fluid passage extends between the top portion and the opposing bottom portion; 
 wherein the bottom portion comprises a spherical external surface that is adapted to contact the ball seat to form a seal; and 
 wherein a dimple is formed in the internal surface, the dimple extending towards the opposing bottom portion. 
 
     
     
       8. The ball valve of  claim 7 , wherein the plurality of chambers is located within the top portion such that the release-by-milling zone extends within the top portion. 
     
     
       9. The ball valve of  claim 1 , wherein the ball is at least partially manufactured using an additive manufacturing process; and
 wherein the ball is formed of a single metal. 
 
     
     
       10. The ball valve of  claim 1 , wherein portions of the body proximate the first and second projections are solid in an entire thickness direction from the internal surface to the external surface. 
     
     
       11. An apparatus comprising:
 a non-transitory computer readable medium; and 
 a plurality of instructions stored on the non-transitory computer readable medium and executable by one or more processors, the plurality of instructions comprising: 
 instructions that cause the manufacture of a ball of a ball valve, the ball comprising an integrally formed single-component body that defines: 
 an external surface; 
 a fluid passage extending through the body, the fluid passage defining an internal surface; and 
 a plurality of internal chambers formed within the body, each internal chamber of the plurality of internal chambers being spaced from the external surface and being spaced from the internal surface; 
 wherein the body forms a first external planar surface and an opposing second external planar surface; 
 wherein the body comprises a first projection extending from the first external planar surface and a second projection extending from the second external planar surface; 
 wherein when the ball is subjected to one or more stresses, a stress concentration is created within a release-by-milling zone of the single-component body, the release-by-milling zone being adjacent to the plurality of internal chambers. 
 
     
     
       12. The apparatus of  claim 11 , wherein the plurality of chambers formed within the body form a lattice structure within the body. 
     
     
       13. The apparatus of  claim 11 ,
 wherein each internal chamber of the plurality of internal chambers is fluidically isolated from the external surface; 
 wherein the body comprises a first material; 
 wherein a second material is accommodated within one internal chamber of the plurality of internal chambers; and 
 wherein the first material is different from the second material. 
 
     
     
       14. The apparatus of  claim 11 , wherein a vent extends from the external surface and to one internal chamber of the plurality of internal chambers. 
     
     
       15. The apparatus of  claim 14 ,
 wherein the body forms a first external planar surface and an opposing second external planar surface; and 
 wherein the vent extends from at least one of the first external planar surface and the second external planar surface. 
 
     
     
       16. The apparatus of  claim 14 , wherein a passageway extends from the one internal chamber to another internal chamber of the plurality of internal chambers. 
     
     
       17. The apparatus of  claim 11 ,
 wherein the body forms a top portion and an opposing bottom portion; 
 wherein the fluid passage extends between the top portion and the opposing bottom portion; 
 wherein the bottom portion comprises a spherical external surface that is adapted to contact a ball seat to form a seal; and 
 wherein a dimple is formed in the internal surface, the dimple extending towards the opposing bottom portion. 
 
     
     
       18. The apparatus of  claim 17 , wherein the plurality of chambers is located within the top portion such that the release-by-milling zone extends within the top portion. 
     
     
       19. The apparatus of  claim 11 , wherein the ball is at least partially manufactured using an additive manufacturing process; and
 wherein the ball is formed of a single metal. 
 
     
     
       20. The ball valve of  claim 11 , wherein portions of the body proximate the first and second projections are solid in an entire thickness direction from the internal surface to the external surface.